Thermal liner for an article of clothing

ABSTRACT

A thermal liner for an article of clothing includes a housing having a top and a bottom, with a thermal material layer interposed therebetween, and a perimeter portion substantially peripherally enclosing the thermal material layer. The perimeter portion can be defined, for example, by peripheral margins of the top and bottom that are sealed together, or by a separate frame interposed between the top and bottom, or by a frame integral with the top and bottom.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of, and claims priority to,U.S. application Ser. No. 11/156,890, filed Jun. 20, 2005, which claimsthe benefit of U.S. Provisional Application No. 60/580,933, filed Jun.19, 2004, the complete disclosures of which are hereby incorporated byreference.

TECHNICAL FIELD

This invention relates generally to clothing and garment articles and,more particularly, to insulating garments as well as insulating garmentarticles such as shoe liners or other clothing inserts that are used inconjunction with an article of clothing.

BACKGROUND OF THE INVENTION

Incorporation of insulating liners with the use of an article ofclothing is known. As used herein, “clothing”, “garment”, or “article ofclothing” includes not only under and outer wear (shirts, blouses,pants, shorts, skirts, underwear, etc.), but also such things asfootwear, gloves, blankets, sleeping bags, and other articles used toprovide protection or comfort against the elements. Such insulatingliners when used in combination with the overlaying article of clothingshields the user against uncomfortably cold or hot temperatures and highlevels of moisture. Various insulating materials for insulating linersthat have been used in the textile industry include felt, fleece,flannel, wool, various forms of latex foam, or the like.

Although flexible and readily adaptable for textile applications, suchmaterials are often provided in relatively thick slabs that can bebulky, thereby requiring the user, for example, to use a larger sizedgarment in order to fit the insulating insert or liner. Also, suchmaterials often do not exhibit effective insulative properties inextremely high or extremely low temperature-related environments.

Silica aerogels have been known to exhibit excellent thermal insulationperformance and have been readily adapted for use in high temperaturethermal insulation and cryogenic thermal insulation applicationsincluding, for example, advanced space suit designs by NASA. Aerogels,as that term is used herein, include polymers with pores with less than50 nanometers in porous diameter. In a process known as sol-gelpolymerization, monomers are suspended in solution and react with oneanother to form a sol, or collection, of colloidal clusters. The largermolecules then become bonded and cross-linked, forming a nearly solidand transparent sol-gel. An aerogel of this type can be produced bycarefully drying the sol-gel so that the fragile network does notcollapse.

Thermal insulation blankets using aerogels have been developed, andaerogel materials are now commercially available in which the aerogel isimpregnated or otherwise incorporated into a carbon-based media. Onedifficulty with using silica aerogels is that the aerogel tends to bedusty, even when supported by a carrier material. If the aerogelmaterial is not properly contained and sealed within the liner assembly,the dust particles may escape the liner and into the atmosphere therebydiminishing the effective insulative life of the insulating liner.

Thus, it is an object of the present invention to provide an insulatinglining for an article of clothing that effectively insulates against hotand cold temperature conditions as well as against moisture, whilereducing or even eliminating the loss of the aerogel dust.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a thermal linerfor an article of clothing includes a housing having a top and a bottomwherein a thermal material layer is interposed therebetween, and furtherhaving a perimeter portion substantially peripherally enclosing thethermal material layer.

In accordance with another aspect of the present invention, a thermalliner for an article of clothing includes a housing including a firstlayer and a second layer, and a frame interposed therebetween, whereinan insulating layer is interposed between the first and second layersand is peripherally enclosed by the frame.

In accordance with a further aspect of the present invention, a thermalliner for an article of clothing includes an injection molded housingincluding an integral top, bottom, and frame defining an opening throughwhich a thermal material layer is inserted and further defining a cavityin which the thermal material layer is disposed. The thermal linerfurther includes a closure member to close the opening.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred exemplary embodiments of the invention will hereinafter bedescribed in conjunction with the appended drawings, wherein likedesignations denote like elements, and wherein:

FIG. 1 is a top view of an insulating liner for a shoe;

FIG. 2 is a cross-sectional view taken along line 2-2 of the insulatingliner shown in FIG. 1;

FIG. 3 is an exploded, perspective view of the formation of theinsulating liner using the formation process of the present invention;

FIG. 4 is an alternative cross-sectional view taken along line 2-2 ofthe insulating liner shown in FIG. 1;

FIG. 5 is a cross-sectional view of a boot taken transversely through atoe end thereof,

FIG. 6 is an alternative cross-sectional view of the boot of FIG. 5;

FIG. 7 is another alternative cross-sectional view of the boot of FIG.5;

FIG. 8 is a top view of a thermal liner for a shoe;

FIG. 9A is a cross-sectional view taken along line 9-9 of the thermalliner shown in FIG. 8;

FIG. 9B is a cross-sectional view of an alternative thermal liner;

FIG. 10 is an exploded top view of another thermal liner for a shoe; and

FIG. 11 is a side view of a portion of the thermal liner of FIG. 10.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the drawings, FIGS. 1 and 2 depict a multiple layerinsulating shoe liner 10 comprising an aerogel-containing insulationlayer 12 encapsulated within two support layers 14, 16 by a hermeticseal. The insulation layer 12 is a relatively thin layer of materialthat is composed of a dust generating aerogel composite including anonporous silica matrix supported or carried by a polymeric, fibroussubstrate. The insulation layer 12 is die-cut and then disposed on anupper surface 13 of the first support layer 14. The liner 10 iscompleted by disposing the second support layer 16, having a wearingmaterial 18 laminated on an upper surface 22 of a polymeric materiallayer 20, over the insulation layer 12. The periphery of the first andsecond support layers 14, 16 are hermetically sealed by a high frequencyor ultrasonic welder for encapsulating the insulation layer 12 betweenthe support layers 14, 16. The insulating shoe liner 10 can include afrontal region 25 which comprises the upper and lower layers 14, 16bonded together without any insulating material 12 therebetween. Thisfrontal region includes raised contour ridges 27 that comprise cut linesalong which the liner 10 can be trimmed to fit various sized shoes.

The insulation layer 12 is composed of a carrier material impregnatedwith an aerogel composite. Studies have shown that aerogel compositesdemonstrate superior insulative properties as opposed to otherinsulators conventionally used in textile, garment and footwearapplications. Based upon their chemical structures, aerogels can havelow bulk densities of about 0.15 g/cm³ or less, and more preferably ofabout 0.03 to 0.3 g/cm³, very high surface areas of generally from about400 to 1,000 m²/g and higher, and more preferably of about 700 to 1000m²/g, high porosity of about 95% and greater, and more preferablygreater than about 97% porosity, and relatively large pore volume withmore than about 3.8 mL/g, and more preferably with about 3.9 mL/g andhigher. The combination of these properties in an amorphous structureprovides low thermal conductivity values of about 9 to 16 mW/m-K at 37°C. and 1 atmosphere of pressure for any coherent solid material.

The carrier used in insulation layer 12 is a polymeric fibrous materialthat effectively carries the aerogel composite material with it. Thecarrier itself can be a carbon-based material, such as a carbon felt orother fibrous material, or can be formed from polyester or any othermaterial suitable for supporting and retaining the aerogel within thecarrier. The fibrous material may include a single type of polymer fiberor may include a combination or matrix of fibers and is somewhat bulky,as compared to the aerogel, and includes some resilience preferably withsome bulk recovery. The use of the carrier minimizes the volume ofunsupported aerogel while avoiding degradation of the thermalperformance thereof. Also, the carrier permits the aerogel to beavailable in the form of a sheet or a roll that contains one continuoussheet or strip that may be easily cut to any desirable size and/or shapeusing conventional textile cutting tools such as die cutting machines,for example. The carrier further provides the aerogel material in a veryflexible state that is very manageable for textile, footwear and othersimilar applications. Suitable aerogel materials for use in the presentinvention include the Spaceloft® AR3101, AR3102 and AR3103 materials aswell as Pyrogel® AR5401, all of which are manufactured by AspenAerogels, Inc. of Marlborough, Mass.

The first support layer 14 is generally composed of an organic polymericmaterial, such as nylon, polystyrene, polypropylene, polyvinyl chloride(PVC), or the like. Specifically, the PVC material is structurallyintact, yet flexible, can be easily cut to a desired size and shape andfurther provides a somewhat sticky or gripping-like surface that isparticularly advantageous for footwear applications. The lower surface23 of the first support layer 14 readily grips and temporarily adheresto the insole of the shoe. For other textile-like applications, othermaterials such as nylon, for example, provides a similar structurallyintegral material suitable for the support layer 14 but does not exhibitsuch a gripping property, thereby making the liner 10 more adaptable forclothing inner linings and for outer linings where a non-grip surface isdesired. In footwear applications, the support layer 14 for the liner 10is preferably composed of PVC foam having a thickness in the range ofabout 1.5 mm to 2.5 mm, and more preferably of about 2.0 mm inthickness.

The second support layer 16 comprises the wearing material 18, about 1.0mm or less in thickness, secured on the upper surface 22 of thepolymeric material layer 20 by lamination, for example. The wearingmaterial 18 is preferably made of a knitted or woven polyester materialthat can be easily cut to the desired size and/or shape of the liner 10,is readily adherable to the polymeric material 20, and further providesa comfortable wearing surface for the user. The polymeric material 20 ispreferably the same PVC foam material that is used for the firststructural layer 14 depending, of course, on the application (e.g.,footwear application) in which the liner will be used.

In the illustrated embodiment, both the first and second support layers14, 16 are structural layers that not only seal the aerogel materialinto an enclosed space, but also provide structural features such ascushioning to the shoe insert. Where such structural features are notneeded, the layers 14, 16 can instead be implemented in other ways thatwill be apparent to those skilled in the art.

In reference now to FIGS. 1-3, the insulating liner 10 is formed by thefollowing process. First, the insulation layer 12 is cut into a suitablesize and shape and laid over an upper surface 24 of a PVC sheet 26. ThePVC sheet 26, after the forming process of the liner 10 provides thefirst structural layer 14. Since the PVC sheet 26 may be provided invarious sizes, more than one insulation layer 12 may be provided on theupper surface 24 to thereby form multiple liner assemblies 10 during asingle insulation liner manufacturing process.

Second, a PVC sheet 28 is pre-preprocessed by laminating a sheet 30 ofthe knitted or woven polyester material 18 thereon. The combinedPVC/polyester panel is then disposed over the insulating layer 12,thereby forming the second structural layer 16 of the insulating liner10.

Third, a high frequency (HF) or ultrasonic welder (not shown) isprovided including a lower platen 31 and upper die plate 32 having thecontours of the shoe liner 10, including the shape, size, andembossments such as dimples 34 (as shown in FIGS. 1 and 3), a logo orthe like. The die plate 32 includes one, two, or more outer die-cuttingsurfaces 36 (only one die cutting surface 36 shown in FIG. 3) forforming one, two or more simultaneous insulating liner assemblies 10.The sheet 26 having the insulating layer 12 thereover as well as thesheet 28 with the laminated material 30 thereon are then positioned onthe platen 31 below the die plate 32, and the die-cutting surface 36 isaligned with the insulating layer 12. The die plate 32 then engages thewearing material 30, and presses the two sheets 26, 28 with theinsulating layer 12 disposed between them together against the platen 31while applying a high frequency of about 10-30 KHz to weld the sheets26, 28 together just outside the periphery of insulating layer 12 tothereby encapsulate the insulating layer 12 therebetween. The die plate32 further die-cuts the sheets 26, 28 with suitable pressure exerted onthe layers 14, 16 from the welder and further simultaneously embossesthe wearing material 18. A hermetic seal is thus formed between the PVCsheets 26, 28 and the insulting liner 10 is cut and formed having thedimples 34 and contour ridges 27, as well as manufacturers' logos orother embossments formed thereon. PVC foam is just one example of asuitable material that is impermeable to air and capable of beinghermetically sealed to another layer of the same material about itsperiphery. Other suitable materials will be known to those skilled inthe art. The welder can be a high frequency plastic welding machine suchas is available from Weldech Electric Industry Co., Ltd. of Taichung,Taiwan (www.weldech.com).

The dimples 34 can comprise areas where the PCV and insulating layersare compressed tightly together such that the dimples compriseindentations in the upper surface. Alternatively, the dimples can beraised areas formed from recesses in the die plate 32. In this latterarrangement, the dimples help provide air flow between the shoe linerand wearer's foot. These dimples can be formed on the first layer 14 aswell, thereby allowing airflow between the insert and insole of theshoe. This latter arrangement is also advantageous during manufacturingsince the layers 12, 14, 16 can be tightly compressed by the die plate32 to squeeze out excess air before hermetically sealing the layers 14,16 during welding. This helps minimize the amount of air trapped in theshoe liner. Furthermore, this manufacturing approach facilitates use ofthicker foam layers such as, for example, a 5 mm foam layer. Duringcompression and welding, the foam can be significantly compressedleaving dimples that protrude by several millimeters.

Turning now to FIG. 4, there is illustrated another embodiment of aninsulating liner for an article of clothing in the form of a shoe liner110. This embodiment is similar in many respects to the embodiment ofFIG. 2 and like numerals that are offset by 100 between the embodimentsgenerally designate like or corresponding elements throughout theseveral views of the drawing figures. Additionally, features of shoeliner 110 that are not explicitly described hereafter can be implementedin the same manner as described above for the first embodiment. The shoeliner 110 includes an aerogel-containing insulation layer 112encapsulated within two support layers 114, 116 by a hermetic seal. Aswith the embodiment shown in FIG. 2, a wearing material 118 is disposedagainst an upper surface 122 of a polymeric material layer 120.Additionally, however, a thermally reflective layer 121 such as metalfoil is disposed between the wearing material 118 and the polymericmaterial layer 120.

The manufacturing process for the liner 110 may be substantially similarto that described above, except that the thermally reflective layer 121may be sandwiched between the wearing material 118 and the polymericmaterial layer 120 before the wearing material 118 is laminated orotherwise attached to the polymeric material layer 120. Alternatively,the wearing material 118 may be welded to the polymeric material layer120 about the periphery of the insulation layer 112 with the thermallyreflective layer 121 trapped therebetween. In any case, the thermallyreflective layer 121 is provided between the insulating layer 112 andthe wearer of the article of clothing. Accordingly, it is alsocontemplated that the thermally reflective layer 121 could be positionedbetween the polymeric material layer 120 and the insulation layer 112 ifdesired.

In general, FIGS. 5 through 7 illustrate embodiments of an article ofclothing generally including an insulating liner integrated into a bootor shoe. As used herein, the terms boot and shoe are interchangeablefootwear articles of clothing. Specifically, in FIG. 5 an insulatingliner is integrated into a boot 200, wherein an aerogel material iscontained and sealed within the boot upper to prevent aerogel dustparticles from escaping the insulating liner. The boot 200 includes amolded sole 202 to provide a foundation for the boot 200 and an outerstructural layer such as a leather upper 204 molded into the sole 202.Disposed on the sole 202 within the confines of the leather upper 204,the boot 200 further includes a foam layer or insert 206 that ispreferably composed of PVC, and a cushion layer or insert 208 disposedon the foam insert 206 that is preferably composed of cork. The boot 200further includes an aerogel upper or layer 212 disposed within theconfines of the leather upper 204, between the leather upper 204 andanother structural layer such as an open-cell foam upper 214 that isalso disposed within the confines of the leather upper 204. Theinsulating liner or lining is thus defined by the aerogel layer 212 andopen-cell foam upper 214, with the aerogel layer 212 being sealedbetween the leather upper 204 and foam layer 214. Aerogel layer 212 canbe the same aerogel/carrier material as insulation layer 12 of the firstembodiment. An open-cell foam insert 216 is disposed on top of thecushion layer 208 within the confines of the open-cell foam upper 214. Athermally reflective layer 221 may be disposed on either or both sidesof the aerogel layer 212. Finally, a thin liner or wearing material 218is preferably composed of polyester material and is applied to insidesurfaces of the open cell foam upper 214 and insert 216.

In general, FIG. 6 illustrates an alternative embodiment of a bootincluding an insulating liner. Specifically, a boot 300 is composed ofthe same components and materials as described above, except that thecushion layer 208 of the boot 200 of FIG. 5 is replaced with an aerogelinsert or layer 308. Accordingly, the boot 300 provides a substantiallycircumferential aerogel layer defined by the aerogel upper 212 and theaerogel insert 308, wherein the aerogel layer is contained and sealedwithin the boot to prevent aerogel dust particles from escaping theinsulating liner.

FIG. 7 illustrates another embodiment of a boot including an insulatingliner. Specifically, a boot 400 is composed of the same components andmaterials as described above, except that the foam insert 206 of theboot 200 of FIG. 5 is replaced with an aerogel insert or layer 406.Accordingly, the boot 400 provides a circumferential aerogel layerdefined by the aerogel upper 212 and the aerogel insert 406, wherein theaerogel layer is again contained and sealed within the boot to preventaerogel dust particles from escaping the insulating liner.

Also, with reference back to FIG. 5, both the insole layers 206 and 208can comprise aerogel material. Alternatively, one or more aerogel layerscould be added adjacent to one or both of the layers 206 and 208. In yetanother embodiment, the upper aerogel layer 212 can be eliminated andinstead the aerogel layer can be used in the insole only forming, ineffect, an integrated shoe liner placed beneath at least the uppermostlayer 218.

FIGS. 8 through 9B illustrate other embodiments of thermal liners. Theseembodiments are similar in many respects to the embodiment of FIGS. 1through 3 and like numerals between the embodiments generally designatelike or corresponding elements throughout the several views of thedrawing figures. Additionally, the description of the previousembodiments are incorporated by reference and the common subject mattermay generally not be repeated here.

FIGS. 8 and 9A depict a thermal liner 510 comprising anaerogel-containing insulation layer 512 encapsulated within a housing511. The thermal liner 510 is preferably a thermal shoe liner 510 butmay be any suitable type of clothing liner. The housing 511 is definedby two support layers 514, 516, and by a frame 515 interposedtherebetween. The insulation layer 512 is sandwiched between the supportlayers 514, 516 and is substantially peripherally enclosed by the frame515, which defines a perimeter portion of the housing 511.

But the perimeter portion need not be a separate component, such as theframe 515. Instead, for example, the perimeter portion could be definedby peripheral margins of the support layers 514, 516 that are fusedtogether or otherwise attached to one another. For example, such aperimeter portion is defined by peripheries of the first and secondsupport layers 14, 16, which are hermetically sealed together to definea housing to enclose the insulation layer 12 of the liner 10 of FIGS. 1and 2. In another example, the perimeter portion could be a unitaryportion integral with both of the support layers 514, 516, as will bedescribed below with regard to FIGS. 10 and 11.

Referring again to FIGS. 8 and 9A, the insulation layer 512 is arelatively thin layer of material that is composed of a dust generatingaerogel composite including a nonporous silica matrix supported orcarried by a polymeric, fibrous substrate. As similarly described abovewith respect to FIGS. 1-3, the frame 515 is die cut and disposed on anupper surface 513 of the first support layer 514. Then, the insulationlayer 512 is die-cut and disposed on the upper surface 513 of the firstsupport layer 514 within the peripheral confine of the frame 515. Theliner 510 is completed by disposing the second support layer 516, havinga wearing material 518 laminated or otherwise carried on an uppersurface 522 of a polymeric material layer 520, over the insulation layer512 and frame 515.

The insulation layer 512 is encapsulated and hermetically sealed withinthe frame 515 and between the support layers 514, 516 of the housing.For example, the upper and lower surfaces of the frame 515, and/orcorresponding peripheral portions of the upper and lower surfaces 513,521 of the support layers 514, 516, are preferably provided with liquidadhesive or pressure sensitive adhesive, wherein heat and pressure areapplied to the frame 515 and support layers 514, 516 during assembly tocreate a hermetic seal therebetween. This process does not result in aliner 510 with impressions, which are typically created during radiofrequency welding. Alternatively, the periphery of the first and secondsupport layers 514, 516 can be hermetically sealed to the upper andlower surfaces of the frame 515 using a high frequency or ultrasonicwelder. This alternative process is similar to the process describedabove with reference to FIGS. 1-3 with an exception; the lower sheet 26would also have the frame 515 thereon, in addition to the insulatinglayer 512 and upper sheet 28, before being positioned on the platen 31.In addition to, or instead of, the sealing techniques above, the housingcan be fastened by sewing the support layers 514, 516 together throughthe frame 515. In any case, the insulating liner 512 can also be adheredto one or both of the layers 514, 516, or can loosely placedtherebetween without attachment.

The thermal shoe liner 510 can include a frontal region 525, whichcomprises the lower and upper support layers 514, 516 bonded to afrontal region of the frame 515 without any insulating material 512therebetween. This frontal region includes raised contour ridges 527that comprise cut lines along which the liner 510 can be trimmed to fitvarious sized shoes. Moreover, the frontal region 525 is but a portionof a peripheral margin surrounding the insulating layer 512 that can betrimmed to a desired size without penetrating, cutting, or otherwisebreaking the seal around the insulating layer 512. Accordingly, theliner 510 can be manufactured for a broad range of shoe sizes such asMen's 7-12 or the like.

The liner 510 materials can be the same or similar to that describedabove with regard to FIGS. 1 through 3. For example, the insulationlayer 512 is composed of a carrier material impregnated with an aerogelcomposite, wherein the carrier used in the insulation layer 512 is apolymeric fibrous material that effectively carries the aerogelcomposite material with it. Preferably, the carrier is an odor-absorbingcarbon-based material. The support layers 514, 516 are generallycomposed of an impermeable organic polymeric material, such aspolyurethane, ethylene vinyl acetate co-polymer (EVA), polyvinylchloride (PVC), or the like. In footwear applications, the supportlayers 514, 516 are preferably composed of a vinyl polymer materialhaving a thickness in the range of about 1.5 mm to 4.0 mm in thickness.The layers 514, 516 are preferably formed from relatively thin materialsto produce a liner 510 that is as thin as possible to provide comfortfor a user. The bottom or first layer 514 can be composed of arelatively durable EVA foam material, which resists tearing and providescushioning. An anti-microbial finish can be applied to the liner 510 toresist growth of bacteria on the product.

Preferably, the support layers 514, 516 are composed of PVC and theframe is composed of a PVC or EVA material to provide a relatively thinproduct. The second support layer 516 can include the wearing material518, which can be natural pigskin or leather, synthetic pigskin orleather, or the like carried or secured on the upper surface 522 of thepolymeric material layer 520 by lamination, for example. If the wearingmaterial 518 is impermeable, then the support layer 516 can include justthe wearing material 518 in place of the polymeric material layer 520,which can be omitted.

In the illustrated embodiment, both the first and second support layers514, 516 are structural layers that, together with the frame 515, notonly seal the aerogel material 512 into an enclosed space, but alsoprovide structural features such as cushioning to the shoe liner 510.Where such structural features are not needed, the layers 514, 516 caninstead be implemented in other ways that will be apparent to thoseskilled in the art. As an alternative, more than one insulating layer512 can be used to obtain greater insulating performance. When two ormore insulating layers 512 are used, the thickness of the frame 515 ispreferably also correspondingly increased.

Alternatively, as shown in FIG. 9B, a thermal liner 510′ can include anupper support layer 516′ comprising an encapsulated phase changematerial. The encapsulated phase change material can be used in hot orcold weather and has the ability to slowly release energy as it changesfrom a solid to a liquid. For example, the encapsulated phase changematerial can be a cold pack. An exemplary phase change material isavailable from Frisby Technologies and is known as Thermasorb™ 95, whichis made from paraffin wax, transforms from solid to liquid at about 35degrees C., and has a latent heat capacity of about 180 J/g.Accordingly, the liner 510′ can be stored inside a freezer prior to useand, once placed inside a shoe, the phase change material absorbs heatfrom a user's foot to help keep the foot more comfortable during hotweather. The encapsulated phase change material can include a phasechange material that is encapsulated and sealed between impermeablepolymeric layers 518′ and 520, one of which can be the polymericmaterial layer 520. The polymeric layers 518′, 520 can be composed ofany suitable material(s) including those mentioned above with respect tothe previously described embodiments. The layers 518, 520 can behermetically sealed about the periphery of the phase change material,such as by applying liquid adhesive or pressure sensitive adhesive, orusing high frequency, ultrasonic, or radio frequency welding, or thelike. Those of ordinary skill in the art are familiar with encapsulatedphase change materials and a detailed discussion is, thus, omitted here.

FIGS. 10 and 11 illustrate another embodiment of a thermal liner. Thisembodiment is similar in many respects to the embodiment of FIGS. 1through 3, and FIGS. 8 through 9B, and like numerals between theembodiments generally designate like or corresponding elementsthroughout the several views of the drawing figures. Additionally, thedescription of the previous embodiments are incorporated by referenceand the common subject matter may generally not be repeated here.

FIGS. 10 and 11 depict a thermal liner 610 comprising a thermal materiallayer 612 encapsulated within a housing 611 defined by two integralsupport layers 614, 616 and a partially integral frame 615 interposedtherebetween. The thermal liner 610 is preferably a thermal shoe liner,but may be any suitable type of clothing liner. The housing 611 is ahollow structure defining a cavity 619 for receiving the thermalmaterial layer 612, and includes a removable closure member 617 that isadapted to be fit into a corresponding opening 623 in the frame 615 ofthe housing 611.

In contrast to the embodiments described above, the housing 611 and itsclosure member 617 are preferably injection molded from an impermeablepolymeric material. Then, the thermal material layer 612 is providedand, as shown, inserted within the cavity 619 defined by the housing 611between an upper surface 613 of the first support layer 614 and a lowersurface 621 of the second support layer 616 within the peripheralconfine of the frame 615. The liner 610 is completed by positioning theclosure member 617 in place and sealingly attaching it to correspondingportions of the support layers 614, 616, and frame 615.

The thermal material layer 612 is encapsulated and hermetically sealedwithin the frame 615 and between the support layers 614, 616 of thehousing 611. For example, the closure member 617 can be provided withliquid adhesive or pressure sensitive adhesive, wherein heat andpressure are applied to the closure member 617, frame 615 and supportlayers 614, 616 during assembly to create a hermetic seal therebetween.Alternatively, the closure member 617 can be hermetically sealed tocorresponding portions of the frame 615 and upper and lower surfaces ofthe housing 611 using high frequency, ultrasonic, or radio frequencywelding. Alternatively, the thermal material layer 612 can be separatelyencapsulated and hermetically sealed prior to being assembled within thehousing 611. In this case, the closure member 617 would not have to behermetically sealed to the rest of the housing 611. Instead, the closuremember 617 could be mechanically connected to the housing 611,interference fit to the housing 611, or the like.

The liner 610 materials can be the same or similar to that describedabove with regard to FIGS. 1 through 3 and/or FIGS. 8 through 9B. Forexample, the housing 611 is preferably composed of an impermeableorganic polymeric material, such as silicone, polyvinyl chloride (PVC),or the like. Also, an anti-microbial finish can be applied to the liner610 to resist growth of bacteria on the product. In another example, thethermal material layer 612 can be an insulation layer such as arelatively thin layer of material that is composed of a dust generatingaerogel composite including a nonporous silica matrix supported orcarried by a polymeric, fibrous substrate. More specifically, such aninsulation layer can comprise a carrier material impregnated with anaerogel composite, wherein the carrier is a polymeric fibrous materialthat effectively carries the aerogel composite material with it.Alternatively, the thermal material layer 612 can be a phase changematerial. Those skilled in the art will recognize that thermal materialsinclude phase change materials and insulation materials. Accordingly,the insulation layer and phase change material layer are interchangeablewithin any given liner housing design.

The liner 610 can be manufactured according to any suitable method. Forexample, the thermal material layer 612 can be encapsulated betweenimpermeable polymeric materials and provided as a sub-assembly to beassembled into the housing 611, or can be a loose component that isassembled into the housing 611. In another example, the thermal materiallayer can be an aggregate that is injected, poured, or otherwiseintroduced into the cavity of the housing 611. In a further example, anover-molding process can be used wherein the thermal material layer 612may first be inserted into a mold of a molding machine, and then thehousing 610 is injection molded therearound. Generally, over-moldingmethods are well known to those of ordinary skill in the art.

In the illustrated embodiment, both the first and second support layers614, 616 are structural layers that, together with the frame 615 andclosure member 617, not only seal the thermal material layer 612 into anenclosed space, but also provide structural features such as cushioningto the shoe liner 610. As an alternative, more than one thermal materiallayer 612 can be used to obtain greater insulating performance. When twoor more thermal material layers 612 are used, the thickness of the frame615 is preferably also correspondingly increased.

It is to be understood that the foregoing description is not adescription of the invention itself, but of one or more preferredexemplary embodiments of the invention. The invention is not limited tothe particular embodiment(s) disclosed herein, but rather is definedsolely by the claims below. Furthermore, the statements contained in theforegoing description relate to particular embodiments and are not to beconstrued as limitations on the scope of the invention or on thedefinition of terms used in the claims, except where a term or phrase isexpressly defined above or where the statement specifically refers to“the invention.” Various other embodiments and various changes andmodifications to the disclosed embodiment(s) will become apparent tothose skilled in the art. For example, the insulating liner 10 canfurther include a cushion layer disposed between the structural layers14, 16 in addition to the insulating layer 12. Also, although the abovedescription refers to both aerogels and aerogel composites, it will beappreciated by those skilled in the art that the aerogel compositescomprise aerogels that have been formed with another substance, and thateither aerogels per se or aerogel composites can be used withoutdeparting from the scope of the invention. All such other embodiments,changes, and modifications are intended to come within the scope of theappended claims.

As used in this specification and appended claims, the terms “forexample” and “such as,” and the verbs “comprising,” “having,”“including,” and their other verb forms, when used in conjunction with alisting of one or more components or other items, are each to beconstrued as open-ended, meaning that that the listing is not to beconsidered as excluding other, additional components or items. Otherterms are to be construed using their broadest reasonable meaning unlessthey are used in a context that requires a different interpretation.

1. A thermal liner for an article of clothing, comprising: a thermalmaterial layer; and a housing having a top and a bottom wherein thethermal material layer is interposed therebetween, and further having aperimeter portion substantially peripherally enclosing the thermalmaterial layer.
 2. The thermal liner of claim 1, wherein the perimeterportion is defined by peripheral margins of the top and bottom, whereinthe peripheral margins are sealed together.
 3. The thermal liner ofclaim 1, wherein the perimeter portion is defined by a separate frameinterposed between the top and bottom.
 4. The thermal liner of claim 1,wherein the perimeter portion is defined by a frame integral with thetop and bottom.
 5. The thermal liner of claim 1, wherein the thermalmaterial layer is an insulating layer sealed between the top and bottom,wherein the insulating layer comprises an aerogel material.
 6. Thethermal liner of claim 5, wherein the bottom is an impermeable firstlayer, the top includes an impermeable second layer, and the frame issealingly attached therebetween.
 7. The thermal liner of claim 6,wherein the second layer includes an impermeable polymeric material anda wearing material applied thereto.
 8. The thermal liner of claim 6,wherein the second layer includes an encapsulated phase change material.9. The thermal liner of claim 1, wherein the housing is injection moldedsuch that the top, bottom, and frame are integral and the housingdefines a cavity.
 10. The thermal liner of claim 9, wherein the housingalso includes a closure member and the frame of the housing includes anopening to receive the thermal material layer into the cavity and aclosure member to close the housing.
 11. The thermal liner of claim 10,wherein the closure member is sealingly attached to correspondingportions of the top, bottom, and frame.
 12. The thermal liner of claim9, wherein the thermal material layer is at least one of anaerogel-containing insulating material or a phase change material.
 13. Athermal liner for an article of clothing, comprising: an insulatinglayer; and a housing including a first layer and a second layer, and aframe interposed therebetween, wherein the insulating layer isinterposed between the first and second layers and peripherally enclosedby the frame.
 14. The thermal liner of claim 13, wherein the bottom isan impermeable first layer, the top includes an impermeable secondlayer, the frame is sealingly attached therebetween, and the insulatinglayer comprises an aerogel material.
 15. The thermal liner of claim 13,further comprising a frontal region defined by portions of the first andsecond layers bonded together without said insulating layer therebetweenand including contour lines identifying cut lines along which the linermay be trimmed to various sizes.
 16. The thermal liner of claim 13,wherein the second layer includes an encapsulated phase change material.17. A thermal liner for an article of clothing, comprising: a thermalmaterial layer; and an injection molded housing including an integraltop, bottom, and frame defining an opening through which the thermalmaterial layer is inserted and further defining a cavity in which thethermal material layer is disposed, and further including a closuremember to close the opening.
 18. The thermal liner of claim 17, whereinthe closure member is sealingly attached to corresponding portions ofthe top, bottom, and frame.
 19. The thermal line of claim 17, whereinthe thermal material layer is separately encapsulated before beinginserted into the housing.
 20. The thermal liner of claim 17, whereinthe thermal material layer is at least one of an aerogel-containinginsulating liner or a phase change material.